Repairable plastic pallet with removable support blocks and associated methods

ABSTRACT

A pallet top deck, a bottom deck, and spaced apart support blocks coupled between the top and bottom decks. Each support block includes an inner wall surrounding an interior opening, an outer wall surrounding the inner wall, and a plurality of ribs extending between the inner and outer walls. First and second upper tabs extend outwards from upper surfaces of the inner wall, with each upper tab comprising an angled contact surface for engaging the top deck. The angled contact surfaces of the first and second upper tabs are oriented in a first direction. First and second lower tabs extend outwards from lower surfaces of the ribs, with each tab comprising an angled contact surface for engaging the bottom deck. The angled contact surfaces of the first and second lower tabs are oriented in a second direction that is orthogonal to the first direction.

RELATED APPLICATIONS

This application is a continuation of application Ser. No. 16/421,677filed May 24, 2019 which claims the benefit of provisional applicationSer. No. 62/678,402 filed May 31, 2018, which are hereby incorporatedherein in their entireties by reference.

BACKGROUND

Plastic pallets are customarily used to transport and store goods. Aplastic pallet typically includes an upper deck and a lower deckseparated by support blocks. The support blocks define a gap or openingbetween the upper and lower decks for receiving the tines from aforklift or pallet jack for moving the pallet.

In terms of durability, plastic pallets are susceptible to damage fromimpacts with the sharp metal tines of the forklift or pallet jack. Inaddition, if the tines are inserted too far between the upper and lowerdecks such that the wheels of the forklift or pallet jack are resting onthe lower deck, then the upper deck becomes separated from the lowerdeck when the tines are lifted.

Depending on the extent of the damage to the plastic pallet, it may berepaired at a cost far less than replacing the entire plastic pallet.There are many types of repairable plastic pallets, as disclosed in U.S.Pat. Nos. 4,843,976; 5,413,052; and 5,791,261, for example. Even in viewof these repairable plastic pallets, there is still a demand to increasedurability, strength and reparability of plastic pallets.

SUMMARY

A pallet includes a top deck, a bottom deck, and a plurality of spacedapart support blocks coupled between the top and bottom decks andforming an opening therebetween for receiving a lifting member. The topdeck has spaced apart upper and lower surfaces, with the lower surfacehaving a plurality of top deck tab openings. The bottom deck has spacedapart upper and lower surfaces, with the upper surface having aplurality of bottom deck tab openings.

Each support block comprising an inner wall having a rectangular shapesurrounding an interior opening, an outer wall having a rectangularshape surrounding the inner wall, and a plurality of ribs extendingbetween the inner and outer walls.

At least one first upper tab extends outwards from upper surfaces of theinner wall, with each upper tab comprising an angled contact surface forengaging one of the top deck tab openings. At least one second upper tabextends outwards from the upper surfaces of the inner wall, with eachtab comprising an angled contact surface for engaging one of the topdeck tab openings. The angled contact surfaces of the at least one firstand second upper tabs are oriented in a first direction.

At least one lower tab extends outwards from lower surfaces of theplurality of ribs, with each tab comprising an angled contact surfacefor engaging one of the bottom deck tab openings. At least one secondlower tab extends outwards from the lower surfaces of the plurality ofribs, with each tab comprising an angled contact surface for engagingone of the bottom deck tab openings. The angled contact surfaces of theat least one first and second lower tabs are oriented in a seconddirection that is orthogonal to the first direction.

The upper surfaces of the outer wall are coplanar with upper surfaces ofthe inner wall, and wherein lower surfaces of the outer wall arecoplanar with lower surfaces of the inner wall.

The upper surfaces of the ribs are coplanar with upper surface of theinner and outer walls, and wherein the lower surfaces of the ribs arecoplanar with lower surfaces of the inner and outer walls.

The angled contact surfaces of the at least one first and second uppertabs face away from each other.

The angled contact surfaces of the at least one first and second lowertabs face towards each other.

The at least one first upper tab is aligned with the at least one secondupper tab.

Each top deck opening includes a flange, and wherein each upper tabcomprises a shoulder opposite the angled contact surface for engagingthe flange in a respective top deck tab opening. The angled contactsurface of each upper tab is configured to flexibly contact the flangein the respective top deck tab opening before the shoulder engages theflange when the top deck is coupled to the plurality of support blocks.

Each support block comprises a pair of spaced apart cap surfaces carriedby the upper surface of the inner wall to cover a portion of theinterior opening.

The at least one first lower tab may be aligned with the at least onesecond lower tab. Each bottom deck opening includes a flange, andwherein each lower tab comprises a shoulder opposite the angled contactsurface for engaging the flange in a respective bottom deck tab opening.

The top deck, the bottom deck and each support block may compriseplastic.

Another aspect is directed to a support block for a pallet as describedabove.

Yet another aspect is directed to a method for making a pallet as alsodescribed above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are upper and lower perspective views of a repairableplastic pallet in accordance with the disclosure.

FIG. 3 is an exploded view of the repairable plastic pallet shown inFIG. 1.

FIGS. 4 and 5 are upper and lower perspective views of a single quadrantof the full size pallet shown in FIG. 1.

FIGS. 6 and 7 are top and bottom views of the top deck shown in FIG. 1.

FIG. 8 is a partial cross-sectional view of the top deck shown in FIG. 1exposing structure support members.

FIG. 9 is a lower perspective view of a single quadrant of the full sizepallet shown in FIG. 1.

FIG. 10 is a bottom view of the single quadrant shown in FIG. 9.

FIGS. 11 and 12 are cross-sectional views of the quadrant shown in FIG.9 taken along line AA.

FIGS. 13 and 14 are cross-sectional views of the quadrant shown in FIG.9 taken along line BB.

FIG. 15 is a partial upper perspective view of the top deck with agrommet in place in accordance with the disclosure.

FIG. 16 is a partial upper perspective view of the top deck shown inFIG. 15 with the grommet removed.

FIG. 17A is a cross-sectional view of the top deck shown in FIG. 15taken along line CC.

FIG. 17B is a cross-sectional view of the top deck shown in FIG. 15taken along line DD.

FIGS. 18A-18E are various views of the grommet shown in FIG. 15.

FIG. 19 is a partial perspective view of an underside of the top deckshown in FIG. 1 with a support block recess having a retaining wall.

FIGS. 20 and 21 are top and bottom views of the bottom deck shown inFIG. 1.

FIG. 22 is a partial perspective view of the bottom deck shown in FIG. 1with the support structure positioned within the open channels.

FIG. 23 is a cross-sectional perspective view of the bottom deck shownin FIG. 1 with a raised channel floor for the support structure.

FIG. 24 is a partial perspective view of a top side of the bottom deckshown in FIG. 1 with a support block recess having a retaining wall.

FIGS. 25 and 26 are upper and lower perspective views of one of thelarge support blocks illustrated in FIG. 1.

FIGS. 27 and 28 are side and end views of the large support blockillustrated in FIG. 25.

FIG. 29 is a cross-sectional perspective view of the large support blockillustrated in FIG. 25.

FIG. 30 is a partial perspective view of the top deck illustrated inFIG. 1 separated from the support blocks in the bottom deck.

FIGS. 31 and 32 are partial cross-sectional views of the plastic palletillustrated in FIG. 1 through a short side and a long side of one of thelarge support blocks.

FIGS. 33 and 34 are upper and lower perspective views of one of thesmall support blocks illustrated in FIG. 1.

FIGS. 35 and 36 are side and end views of the large support blockillustrated in FIG. 33.

FIG. 37 is a cross-sectional perspective view of the small support blockillustrated in FIG. 33.

FIG. 38 is a partial cross-sectional view of the plastic palletillustrated in FIG. 1 through one of the small support blocks.

DETAILED DESCRIPTION

The present description is made with reference to the accompanyingdrawings, in which exemplary embodiments are shown. However, manydifferent embodiments may be used, and thus the description should notbe construed as limited to the particular embodiments set forth herein.Rather, these embodiments are provided so that this disclosure will bethorough and complete. Like numbers refer to like elements throughout.

Referring initially to FIGS. 1-3, the illustrated repairable plasticpallet 50 includes a top deck 60, a bottom deck 70 and removable supportblocks 80, 90 separating the top and bottom decks 60, 70. The supportblocks 80, 90 are positioned to enable 4-way entry by pallet handlingequipment, such as a forklift or pallet jack.

The plastic pallet 50 is a standard full size pallet having dimensionsof 40 inches by 48 inches, for example. These dimensions are exemplaryand are not to be limiting. The plastic pallet 50 may be configured toaccommodate other sizes, such as a half or quarter size pallet, forexample.

An exploded view of the plastic pallet 50 is provided in FIG. 3. The topdeck 60 includes a support structure made up of individual supportstructure members 100. Each support structure member 100 is insertedinto a respective side opening 52 within the top deck 60. Each sideopening 52 is aligned with a channel that is to receive a supportstructure member 100. The bottom deck 70 also includes a supportstructure 110. The support structure 110 may be formed as a single unitthat is dropped into open channels 72 within the bottom deck 70 duringassembly of the plastic pallet 50. Alternatively, the support structure100 may be formed as individual support structure members that aredropped into the open channels 72 within the bottom deck 70 duringassembly of the plastic pallet 50.

The illustrated plastic pallet 50 includes 9 support blocks, wherein 6of the support blocks 80 are referred to as large support blocks. Theremaining 3 support blocks 90 are referred to as small support blocks.If any of the support blocks 80, 90 become damaged, the plastic pallet50 may be repaired by replacing only the damaged support blocks 80, 90.Similarly, if the top or bottom deck 60, 70 becomes damaged, the plasticpallet 50 may be repaired by replacing the damaged top or bottom deck60, 70.

The large support blocks 80 are at the corners of the plastic pallet 50and between the corners on one of the opposing sides of the plasticpallet 50. The small support blocks 90 are between the corners on theother opposing sides of the plastic pallet 50, and in the center of theplastic pallet 50.

Also shown in the exploded view are grommets 120 that are inserted intoopenings 124 within the top deck 60. The grommets 120 are exposed on theupper surface 61 of the top deck 60, and are exposed on an opposinglower surface 63 of the top deck 60. The upper surface 61 of the plasticpallet 50 may also be referred to as a product support surface. Exposureof the grommets 120 on the product support surface helps to provide abetter grip when items are placed thereon. Exposure of the grommets 120on the lower surface 63 of the top deck 60 helps to provide a bettergrip with pallet handling equipment.

The top deck 60 and the bottom deck 70 respectively have symmetricalquadrants 130. Upper and lower perspective views of a single quadrant130 of the plastic pallet 50 are illustrated in FIGS. 4 and 5.

Even though only a single quadrant 130 is shown, the top and bottomdecks 60, 70 are respectively formed as monolithic units with all fourquadrants integrated together for each deck 60, 70. The symmetricalquadrants do not require positioning of the top and bottom decks 60, 70in any particular orientation when joined with the support blocks 80, 90other than having the short sides aligned together and the long sidesaligned together.

The top deck 60 includes a product support surface 61 as illustrated inFIG. 6, and an underside 63 as illustrated in FIG. 7. The top deck 60includes support structure members 100 for strengthening the plasticpallet 50. There are 6 channels 102 extending through the top deck 60.Direction of the channels are marked by arrows 102(1)-102(6). Eachchannel 102 extends from one side of the top deck 60 to the other sideof the top deck 60.

Each support structure member 100 is inserted through a respective sideopening 52 within the top deck 60. In one embodiment, there is a sideopening 52 at each end of the channels 102. In other embodiments, thereis a side opening 52 at only one end of each channel 102, with the otherend being closed off by the side or edge of the top deck 60 or by plugs.Once the support structure members 100 have been inserted into theirrespective channels 102, plugs are used to close off the remaining sideopenings 52.

The top deck 60 includes openings 104 to expose the support structuremembers 100 within the channels 102. In the illustrated top deck 60,there are 8 openings 104 per channel 102 on the long side of the topdeck 60, and 6 openings 104 per channel 102 on the short side of the topdeck 60. The size of the opens 104 within the top deck 60 may vary, aswell as the number of openings.

A partial cross-section view of the top deck 60 is provided in FIG. 8exposing two of the support structure members 100. One of the supportstructure members 100 blocks the other support structure member 100 atintersecting channels 102. Each support structure member 100 may beconfigured as a pultrusion having an I-beam shape. The support structuremembers 100 are self-contained within the top deck 60 and do not contactthe support blocks 80, 90. The support structure members 100 are notlimited to having an I-beam shape. The support structure members 100 maybe formed having other cross-sectional shapes.

One aspect of the disclosure is directed to the top deck 60 including atleast one deck scoop area on an underside thereof, with a thickness ofthe top deck 60 being reduced in the at least one deck scoop area toreduce influence of top deck deflection on ability of the lifting memberto pass through the opening between the top and bottom decks 60, 70. Inone embodiment, the top deck 60 may include a single large-sized deckscoop area centered on an underside 63 of the top deck 60. In otherembodiments, the top deck 60 may include multiple small-sized deck scoopareas spaced apart on the underside 63 of the top deck 60.

As noted above, the illustrated top deck 60 is configured with foursymmetrical quadrants 130, with an underside of one of the quadrants 130illustrated in FIGS. 9 and 10 at different angles. Each quadrant 130includes at least one deck scoop area. In the illustrated embodiment,each quadrant 130 includes a pair of deck scoop areas 62, 64. The pairof deck scoop areas 62, 64 may also be referred to as carvings 62, 64.The deck scoop areas 62, 64 respectively reduce the thickness of the topdeck 60 within each quadrant 130.

Deck scoop area 62 may be referred to as a first deck scoop area, anddeck scoop area 64 may be referred to as a second deck scoop area. Thesecond deck scoop area 64 may be larger in size than the first deckscoop area 62. In other embodiments, the deck scoop areas 62, 64 may beequal in size. The first deck scoop area 62 may have an ellipticalshape, and the second deck scoop area 64 may have a circular or ovalshape. In other embodiments, the first and second deck scoop areas 62,64 may have the same shape.

The underside 63 of the top deck 60 is made up of ribs that are exposed.The first deck scoop area 62 includes a hand grip opening 72 having arectangular shape. The hand grip opening 72 is centered within the firstdeck scoop area 62. The hand grip opening 72 is at a peak of thecurvature within the first deck scoop area 62. This peak corresponds tothe minimum thickness point of the top deck 60 within the first deckscoop area 62.

The hand grip opening 72 includes a wall 74 that extends from an uppersurface 61 of the top deck 60 to an underside 63 of the ribs 76, 78within the first deck scoop area 62. Ribs 76 extend in a firstdirection, and ribs 78 extend in a second direction orthogonal to thefirst direction.

The first deck scoop area 62 in each quadrant 130 is adjacent an outerexposed side 65 of the top deck 60. An outer perimeter area 82 of thequadrant 130 between the outer exposed side 65 and the first deck scooparea 62 has a uniform thickness, and is not part of the first deck scooparea 62. The outer perimeter area 82 of the quadrant 130 extends arounda perimeter of the top deck 60 for all four quadrants.

The second deck scoop area 64 is separated from the first deck scooparea 64 by an inner portion area 84 of the quadrant. The inner portionarea 84 also has a uniform thickness and is not part of the first orsecond deck scoop area 62, 64.

The second deck scoop area 64 includes a plurality of spaced apartopenings 131. The openings 131 may be divided into spaced apart openingsections 132 that are laid out in a grid pattern. Each opening section132 has a pattern of openings that is symmetrical to each of the otheropening sections 132 within the second deck scoop area 64.

The ribs within the second deck scoop area 64 include ribs 86 extendingin a first direction and ribs 87 extending in a second directionorthogonal to the first direction. The ribs within the second deck scooparea 64 further include ribs 88 extending between circular shaped ribs89. The circular shaped ribs 89 are at an intersection of ribs 86, 87.Ribs 88 form a crisscross pattern between adjacent circular shaped ribs89.

A cross-section view of the quadrant 130 illustrated in FIG. 11 alongline AA is provided in FIG. 12. This cross-sectional view shows thefirst and second deck scoop areas 62, 64 side by side.

Similarly, a cross-section view of the quadrant 130 illustrated in FIG.13 along line BB is provided in FIG. 14. This cross-sectional view onlyshows the second deck scoop area 64 since the first deck scoop area 62is behind the second deck scoop area 64.

A method making a plastic pallet 50 with at least one deck scoop area62, 64 includes forming a top deck 60, forming a bottom deck 70, andcoupling a plurality of spaced apart support blocks 80, 90 between thetop and bottom decks 60, 70 and forming an opening therebetween forreceiving a lifting member. As discussed above, the top deck 60 includesat least one deck scoop area 62, 64 on an underside 63 thereof. Athickness of the top deck 60 is reduced in the at least one deck scooparea to reduce influence of top deck deflection on ability of thelifting member to pass through the opening between the top and bottomdecks 60, 70.

Referring now to FIGS. 15-18, the use of grommets 120 within the topdeck 60 will be discussed. The grommets 120 advantageously provide abetter grip when items are placed on an upper surface 61 of the top deck60, and also provide a better grip with forklift tines on an underside63 of the top deck 60. Suitable materials for the grommets 120 includenatural rubber and synthetic rubber, for example.

The grommets 120 are spaced around the edges of the top deck 60. In theillustrated embodiment, there are 8 grommets 120 spaced adjacent aperimeter of the top deck 60, with each grommet 120 being centeredbetween a pair of adjacent support blocks, such as supports blocks 80,90. The number, location and size of the grommets 120 may vary asreadily appreciated by those skilled in the art. Although notillustrated, grommets 120 may be placed in a central area of the topdeck 60, i.e., away from the perimeter of the top deck 60.

Each grommet 120 is inserted into a rectangular shaped grommet opening124 that extends through the top deck 60. The grommet opening 124 isstepped down from the upper surface 61 of the top deck 60 to form arecessed shelf 126. The grommet opening 124 has a first perimeter sizeabove the recessed shelf 126.

Below the recessed shelf 126, the grommet opening 124 has a secondperimeter size that is less than the first perimeter size. Includedwithin the second perimeter size is a divider 128. An upper surface ofthe divider 128 is recessed from the recessed surface 126, and a lowersurface of the divider 128 continues to the underside 63 of the top deck60. The divider 128 requires that a lower portion of each grommet 120have a slit so as to accommodate the divider 128, as illustrated in FIG.17A.

Each grommet 120 includes a lip 133 for engaging the recessed shelf 126.An upper surface 135 of each grommet 120 is flat and elevated above theupper surface 61 of the top deck 60. The transition 137 between theupper surface 135 and the lip 133 of each corresponding grommet 120 iscurved.

While an upper half of each grommet 120 is solid, a corresponding lowerhalf is divided into sections 302. The sections 302 are on adjacentsides of the divider 128. A bottom surface of each section 302, whichextends through to the underside 63 of the top deck 60, is flared 306for engaging the underside 63 of the top deck 60.

The cross-sectional view of the grommet 120 provided in FIG. 17A istaken along lines CC in FIG. 15. The cross-sectional view of the grommet120 provided in FIG. 17B is taken along lines DD in FIG. 15.

Referring now FIGS. 18A-18E, a grommet 120 will be discussed in greaterdetail. Each grommet 120 includes an upper section 300, at least onemid-section 302, and at least one lower section 304. The grommet 120 maybe formed as a single monolithic unit from natural rubber or syntheticrubber. The grommet 120 is rectangular shaped to match therectangular-shaped grommet opening 124. In other embodiments, thegrommet 120 and the grommet opening 124 may have a different shape, suchas square or circular, for example.

The upper section 300 includes a lower lip 133 that is to rest on therecessed shelf 126, and an outer exposed surface of the upper section300 is to extend in height the top deck 60. The outer exposed surface isto provide a better grip when items are placed on an upper surface 61 ofthe top deck 60. The at least one mid-section 302 is adjacent the lowerlip 133 and extends from the upper section 300 to an underside 63 of thetop deck 60.

The at least one lower section 304 extends from the at least onemid-section 302, and includes a pair of spaced apart lips 306 to rest onthe underside 63 of the top deck 60. An outer exposed surface of the atleast one lower section 304 extends in height below the underside 63 ofthe top deck 60. The outer exposed surface is to provide a better gripwhen forklift tines make contact with an underside 63 of the top deck60.

As noted above, each grommet opening 124 in the top deck 60 includes adivider 128. The divider 128 includes a lower surface even with theunderside 63 of the top deck 60, and an upper surface that is below therecessed shelf 126. In other embodiments, the lower surface of thedivider 128 may not be even with the underside 63 of the top deck 60,and the upper surface of the divider 128 may be even with the recessedshelf 126.

To accommodate for the divider 128, the at least one mid-section 302comprises a pair of spaced apart mid-sections 302, with each mid-section302 being separated by the divider 128. Similarly, the at least onelower section 304 comprises a pair of lower sections 304, with eachlower section 304 extending from a respective mid-section 302.

Sidewalls of the illustrated mid-sections 302 have a square waveformshape formed by spaced apart vertical section protrusions 310 withrecesses 312 therebetween. In other embodiments, sidewalls of themid-sections 302 may have completely flat surfaces.

Referring now to FIG. 19, the top deck 60 is configured to includerecesses 140 for the support blocks 80, 90. The recesses 140 arerespectively sized to receive the upper end of the support blocks 80,90. The recesses 140 form a recessed pocket providing a retaining wall142 to laterally support the upper end of the support blocks 80, 90. Theretaining wall 142 may also be referred to as a retaining rib.

The bottom deck 70 will now be discussed in greater detail. A top viewof the bottom deck 70 is illustrated in FIG. 20, and a bottom view ofthe bottom deck 70 is illustrated in FIG. 21. The bottom deck 70includes a support structure 110, as illustrated in FIG. 22.

The support structure 110 is formed as a single monolithic unit as shownin the exploded view of the plastic pallet 50 illustrated in FIG. 3. Thesupport structure 110 is dropped into open channels 72 within the bottomdeck 70 during assembly of the plastic pallet 50, as illustrated in FIG.22. Alternatively, the support structure 100 may be formed as individualsupport structure members that are dropped into the open channels 72within the bottom deck 70 during assembly of the plastic pallet 50.

The support structure 110 has a square shape with an opening extendingtherethrough. The support blocks 80, 90 make contact with the supportstructure 110 when the plastic pallet 50 is assembled. The supportstructure 110 is not limited to a square shape. The support structure110 may be formed having other shapes.

A cross-sectional view of the bottom deck 70 and support structure 110is provided in FIG. 23 to illustrate a raised channel floor 160 for thesupport structure 110. The raised channel floor 160 helps to protect thesupport structure 110 from being exposed should the underside 73 of thebottom deck 70 wear thin from use. The bottom or floor 160 of thechannel 72 is raised from the lowermost surface 162 of the bottom deck70. Legs 164 are positioned under the channel floor 160. The lowermostsurface 162 and the legs 164 correspond to the underside of the bottomdeck 70.

Referring now to FIG. 24, the bottom deck 70 is configured to includerecesses 170 for the support blocks 80, 90. The recesses 170 arerespectively sized to receive the lower end of the support blocks 80,90.

The recesses 170 form a recessed pocket providing a retaining wall 172to laterally support the lower end of the support blocks 80, 90. Theretaining wall 172 may also be referred to as a retaining rib.

Referring now to FIGS. 25-32, the large support blocks 80 will bediscussed in greater detail. The large support blocks 80 advantageouslyinclude upper snaps 200, 201 for engaging the top deck 60 and lowersnaps 202, 203, 204, 205 for engaging the bottom deck 70. The upper andlower snaps 200-205 may also be referred to as upper and lower tabs200-205.

Should any one of the support blocks 80 become damaged, the top andbottom decks 60, 70 may be separated from the support blocks 80, 90 viatheir corresponding upper and lower tabs 200-205 so that the damagedsupport block 80 may be replaced.

The top deck 60 has spaced apart upper and lower surfaces 61, 63. Thelower surface 63 has a plurality of top deck tab openings 217, as shownin FIG. 19. Each large support block 80 includes an inner wall 210having a rectangular shape surrounding an interior opening 220, and anouter wall 212 having a rectangular shape surrounding the inner wall210. The outer wall 212 has an upper surface coplanar with an uppersurface of the inner wall 210, and a lower surface coplanar with a lowersurface of the inner wall 210.

Ribs 214 extend between the inner and outer walls 210, 212. The ribs 214have an upper surface coplanar with an upper surface of the inner andouter walls 210, 212, and a lower surface coplanar with a lower surfaceof the inner and outer walls 210, 212.

A first plurality of upper tabs 200 extend outwards from the uppersurfaces of the inner wall 210 and the ribs 214. Each tab 200 includesan angled contact surface 213 for engaging the top deck tab openings 217as shown in FIG. 28.

A second plurality of upper tabs 201 extend outwards from the uppersurfaces of the inner wall 210 and the ribs 214. Each tab 201 includesan angled contact surface 215 for engaging the top deck tab openings 217as also shown in FIG. 28. The angled contact surfaces 213, 215 of thefirst and second upper tabs 200, 201 face away from each other.

The first upper tabs 200 are aligned with the second upper tabs 201.That is, the upper tabs 200, 201 are grouped together in pairs and faceoutwards.

Each top deck opening 217 includes a flange 230, as illustrated in FIG.31. Each upper tab 200, 201 comprises a shoulder 216, 218 opposite theirrespective angled contact surface 213, 215, as illustrated in FIG. 28,for engaging the flange 230 in a respective top deck tab opening 217.The angled contact surface 213, 215 of each upper tab 200, 201 isconfigured to flexibly contact the flange 230 in the respective top decktab opening 217 before the shoulder 216, 218 engages the flange 230 whenthe top deck 60 is coupled to the support blocks 80.

An interior 220 of the support block 80 is open and does not include anyribs. A portion of the interior 220 is closed off via spaced apart capsurfaces 224 on the upper surface of the inner wall 210. The capsurfaces 224 provide additional support for the support block 80. Theinterior 220 on the lower surface of the support block 80 is open.

A partial view of the top deck 60 separated from a large support block80 and a small support block 90 is illustrated in FIG. 30. The largesupport block 80 is rectangular shaped and has a short side and a longside. A cross-section view of the large support block 80 along the shortside is illustrated in FIG. 31. A cross-section view of the largesupport block 80 along the long side is illustrated in FIG. 32.

Referring now to FIG. 31, each top deck tab opening 217 is adjacent asupport structure member 100 in the top deck 60. Each first and secondupper tab 200, 201 is flexible for engaging the flange 230 in the topdeck tab opening 217.

The bottom deck 70 has spaced apart upper and lower surfaces 71, 73, asshown in FIGS. 20, 21. The upper surface 71 has a plurality of bottomdeck tab openings 219, 221, as shown in FIG. 22. Each bottom deck tabopening 219, 221 is adjacent the support structure 110 in the bottomdeck 70.

Each support block 80 further includes a first plurality of lower tabs202 extending outwards from the lower surfaces of the inner wall 210 andthe ribs 214. Each tab 202 includes an angled contact surface 221, asshown in FIG. 28, for engaging the bottom deck tab openings 219.

A second plurality of lower tabs 203 extend outwards from the lowersurfaces of the inner wall 210 and the ribs 214. Each tab 203 includesan angled contact surface 223, as also shown in FIG. 23, for engagingthe bottom deck tab openings 219. The angled contact surfaces 221, 223of the first and second lower tabs 202, 203 face towards each other. Thefirst lower tabs 202 are aligned with the second lower tabs 203.

Each bottom deck opening 219 includes a flange 232, as illustrated inFIG. 31. Each lower tab 202, 203 includes a shoulder 227, 229 oppositethe angled contact surface 221, 223, as shown in FIG. 28, for engagingthe flange 232 in a respective bottom deck tab opening 219.

The angled contact surface 221, 223 of each lower tab 202, 203 isconfigured to flexibly contact the flange 232 in the respective bottomdeck tab opening 219 before the shoulder 227, 229 engages the flange 232when the bottom deck 70 is coupled to the support blocks 80.

Referring now to FIGS. 25, 26, each support block 80 further includes afirst plurality of additional lower tabs 204 extending outwards from thelower surfaces of the ribs 240. Each tab 204 includes an angled contactsurface 231 for engaging the bottom deck tab openings 221. A secondplurality of additional lower tabs 205 extend outwards from the lowersurfaces of the ribs 240. Each tab 205 includes an angled contactsurface 233 for engaging the bottom deck tab openings 221. The angledcontact surfaces 231, 233 of the first and second additional lower tabs204, 205 face towards each other.

The lower tabs 202, 203 are aligned with the upper tabs 200, 201. Theadditional lower snaps 204, 205 are also grouped together in pairsfacing one another. The orientation of the additional lower snaps 204,205 is orthogonal to the lower snaps 202, 203.

Referring now to FIG. 32, the additional lower tabs 204, 205 areinserted into bottom deck tab openings 221 in the bottom deck 70. Eachtab opening 244 includes a flange 234 recessed therein. Each additionallower tab 204, 205 is flexible for engaging the flange 234.

Half of the snap openings 221 are adjacent the channels 72 that are toreceive the support structure 110. The other half of the snap openings219 are parallel to and spaced away from the channels 72.

Referring now to FIGS. 33-38, the small support blocks 90 will bediscussed in greater detail. The small support blocks 90 advantageouslyinclude snaps 250, 252 for engaging the top and bottom decks 60, 70. Thesnaps 250, 252 may also be referred to as tabs 250, 252.

Should any one of the support blocks 90 become damaged, the top andbottom decks 60, 70 may be separated from the support blocks 80, 90 viatheir corresponding snaps so that the damaged support block 90 may bereplaced.

Each small support block 90 includes an inner wall 260 and an outer wall262 with ribs 264 extending therebetween. The upper snaps 250 aregrouped together in pairs and face each other. The lower snaps 252 arealso grouped together in pairs and face each other. The lower snaps 252are positioned inwards from the upper snaps 250.

An interior 270 of the support block 90 is open and does not include anyribs. The bottom of the interior 270 is closed off via contact surface272 on the lower surface of the support block 90. Adjacent the interior270 at an upper surface of the support block 90 are contact surfaces274. The contact surfaces 274 are between the inner wall 260 and theinterior 270.

Referring now to FIG. 38, each snap opening 280 adjacent a supportstructure member 100 in the top deck 60 includes a lip or protrusion 290recessed therein. Each upper snap 250 is flexible for engaging the lip290.

There is a corresponding snap opening 282 in the bottom deck 70 thatalso includes a lip or protrusion 292 recessed therein. Each lower snap252 is flexible for engaging the lip 292. Each snap opening 282 isadjacent the support structure 110 in the bottom deck 70.

Many modifications and other embodiments will come to the mind of oneskilled in the art having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it isunderstood that the disclosure is not to be limited to the specificembodiments disclosed, and that modifications and embodiments areintended to be included within the scope of the appended claims.

1. A pallet comprising: a top deck having spaced apart upper and lowersurfaces, with the lower surface having a plurality of top deck tabopenings; a bottom deck having spaced apart upper and lower surfaces,with the upper surface having a plurality of bottom deck tab openings;and a plurality of spaced apart support blocks coupled between said topand bottom decks and forming an opening therebetween for receiving alifting member, each support block comprising an inner wall having arectangular shape surrounding an interior opening, an outer wall havinga rectangular shape surrounding said inner wall, a plurality of ribsextending between said inner and outer walls, at least one first uppertab extending outwards from upper surfaces of said inner wall, with eachupper tab comprising an angled contact surface for engaging one of thetop deck tab openings, at least one second upper tab extending outwardsfrom the upper surfaces of said inner wall, with each tab comprising anangled contact surface for engaging one of the top deck tab openings,with the angled contact surfaces of said at least one first and secondupper tabs oriented in a first direction, at least one first lower tabextending outwards from lower surfaces of said plurality of ribs, witheach tab comprising an angled contact surface for engaging one of thebottom deck tab openings, at least one second lower tab extendingoutwards from the lower surfaces of said plurality of ribs, with eachtab comprising an angled contact surface for engaging one of the bottomdeck tab openings, and with the angled contact surfaces of said at leastone first and second lower tabs oriented in a second direction that isorthogonal to the first direction.
 2. The pallet according to claim 1wherein the upper surfaces of said outer wall are coplanar with uppersurfaces of said inner wall, and wherein lower surfaces of said outerwall are coplanar with lower surfaces of said inner wall.
 3. The palletaccording to claim 1 wherein upper surfaces of said ribs are coplanarwith upper surface of said inner and outer walls, and wherein the lowersurfaces of said ribs are coplanar with lower surfaces of said inner andouter walls.
 4. The pallet according to claim 1 wherein the angledcontact surfaces of said at least one first and second upper tabs faceaway from each other.
 5. The pallet according to claim 1 wherein theangled contact surfaces of said at least one first and second lower tabsface towards each other.
 6. The pallet according to claim 1 wherein saidat least one first upper tab is aligned with said at least one secondupper tab.
 7. The pallet according to claim 1 wherein each top deckopening includes a flange, and wherein each upper tab comprises ashoulder opposite the angled contact surface for engaging the flange ina respective top deck tab opening.
 8. The pallet according to claim 7wherein the angled contact surface of each upper tab is configured toflexibly contact the flange in the respective top deck tab openingbefore the shoulder engages the flange when said top deck is coupled tosaid plurality of support blocks.
 9. The pallet according to claim 1wherein each support block comprises a pair of spaced apart cap surfacescarried by the upper surface of said inner wall to cover a portion ofthe interior opening.
 10. The pallet according to claim 1 wherein saidat least one first lower tab is aligned with said at least one secondlower tab.
 11. The pallet according to claim 10 wherein each bottom deckopening includes a flange, and wherein each lower tab comprises ashoulder opposite the angled contact surface for engaging the flange ina respective bottom deck tab opening.
 12. The pallet according to claim1 wherein said top deck, said bottom deck and each support blockcomprises plastic.
 13. A support block for a pallet comprising: an innerwall having a rectangular shape surrounding an interior opening; anouter wall having a rectangular shape surrounding said inner wall; aplurality of ribs extending between said inner and outer walls; at leastone first upper tab extending outwards from upper surfaces of said innerwall, with each upper tab comprising an angled contact surface forengaging one of top deck tab openings in a top deck of the pallet; atleast one second upper tab extending outwards from the upper surfaces ofsaid inner wall, with each tab comprising an angled contact surface forengaging one of the top deck tab openings in the top deck; with theangled contact surfaces of said at least one first and second upper tabsoriented in a first direction; at least one first lower tab extendingoutwards from lower surfaces of said plurality of ribs, with each tabcomprising an angled contact surface for engaging one of bottom deck tabopenings in a bottom deck of the pallet; at least one second lower tabextending outwards from the lower surfaces of said plurality of ribs,with each tab comprising an angled contact surface for engaging one ofthe bottom deck tab openings in the bottom deck; and with the angledcontact surfaces of said at least one first and second lower tabsoriented in a second direction that is orthogonal to the firstdirection.
 14. The support block according to claim 13 wherein the uppersurfaces of said outer wall are coplanar with upper surfaces of saidinner wall, and wherein lower surfaces of said outer wall are coplanarwith lower surfaces of said inner wall.
 15. The support block accordingto claim 13 wherein upper surfaces of said ribs are coplanar with uppersurface of said inner and outer walls, and wherein the lower surfaces ofsaid ribs are coplanar with lower surfaces of said inner and outerwalls.
 16. The support block according to claim 13 wherein the angledcontact surfaces of said at least one first and second upper tabs faceaway from each other.
 17. The support block according to claim 13wherein the angled contact surfaces of said at least one first andsecond lower tabs face towards each other.
 18. The support blockaccording to claim 13 wherein said at least one first upper tab isaligned with said at least one second upper tab.
 19. The support blockaccording to claim 13 wherein said at least one first lower tab isaligned with said at least one second lower tab.
 20. A method for makinga pallet comprising: forming a top deck having spaced apart upper andlower surfaces, with the lower surface having a plurality of top decktab openings; forming a bottom deck having spaced apart upper and lowersurfaces, with the upper surface having a plurality of bottom deck tabopenings; and coupling a plurality of spaced apart support blockscoupled between the top and bottom decks and forming an openingtherebetween for receiving a lifting member, each support blockcomprising: an inner wall having a rectangular shape surrounding aninterior opening, an outer wall having a rectangular shape surroundingthe inner wall, a plurality of ribs extending between the inner andouter walls, at least one first upper tab extending outwards from uppersurfaces of the inner wall, with each upper tab comprising an angledcontact surface for engaging one of the top deck tab openings, at leastone second upper tab extending outwards from the upper surfaces of theinner wall, with each tab comprising an angled contact surface forengaging one of the top deck tab openings, with the angled contactsurfaces of the at least one first and second upper tabs oriented in afirst direction, at least one first lower tab extending outwards fromlower surfaces of the plurality of ribs, with each tab comprising anangled contact surface for engaging one of the bottom deck tab openings,at least one second lower tab extending outwards from the lower surfacesof the plurality of ribs, with each tab comprising an angled contactsurface for engaging one of the bottom deck tab openings, and with theangled contact surfaces of the at least one first and second lower tabsoriented in a second direction that is orthogonal to the firstdirection.